Yes the guy did not do the header structure properly.
I wondering if i should make the window smaller now since i have the chance?
Also maybe spray insulation, should i take that old petrifies wood out?

Hi Neal, i'm thinking to make new wall, then insulation. It is concrete and petrified wood.
Maybe spray insulation? Also the roof is about 4" empty. What i gather you can just use the spray insulation and fill it up, with no vents?

I see what you mean about the header. Originally the window would have been smaller. I think i need a carpenter for this job.

You will have to find out if the whole house is built like this or if it was someones idea of a feature wall. My guess is that if it is all like this you will have to treat it more like a brick building. If that wall continues upstairs the header maybe should be a steel lentle.
I think you have to do more digging to find what you have a ware before you start fixing things. If they did that to every window they will all need fixing.http://www.proudgreenhome.com/blog/6...d-construction

Hi Neal, i will post some pics soon. But it is only the 2 bay 70x48" windows that this fellow DIY'ed, Actually the 2nd window is better. You can see the problem with the first already how he just broke it there.

I'm think is there no high tech fix for this? Why not just put a metal frame in there?

I guess the windows could be replaced. In that case with the as you say 6" sides, i would have to make the window smaller. 70"-12=58"
Just as well. But people around here like big windows, big cars etc.